Flexible Thermoplastic Composite Pipe With Fusion-Bonded Reinforcement
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Solution Overview
Problem
Existing methods for producing thermoplastic composite pipes lack efficiency in creating a robust, flexible, and high-pressure-resistant structure suitable for transporting media over long distances, particularly in onshore and offshore applications.
Innovation Solution
A method involving the extrusion of a thermoplastic pipe followed by the application and consolidation of multiple reinforcing layers using a spiral winding process, where each layer is fusion-bonded to the previous one using infrared heating, creating a multi-layer reinforcing structure that enhances the pipe's strength and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple reinforcing layers are applied using spiral winding process, then the pipe's strength and pressure resistance are improved, but the manufacturing complexity and process time increase
Solution Approach 1:
The thermoplastic pipe is preheated before applying the reinforcing layers, which prepares the surface for better bonding and reduces the complexity of subsequent bonding steps. This preliminary action ensures that the reinforcing layers adhere properly without requiring complex bonding equipment or procedures.
Solution Approach 2:
The reinforcing layers are applied continuously in a spiral winding process, with each layer being immediately consolidated onto the previous one. This continuous process eliminates interruptions and reduces manufacturing complexity compared to discrete, step-by-step layer application methods.
2Stress or pressure
If multiple reinforcing layers are applied using spiral winding process, then the pipe's pressure resistance is improved, but the production time increases
Solution Approach 1:
The spiral winding process applies multiple reinforcing layers in a continuous operation without interruption. The pipe moves through the winding and consolidation processes continuously, eliminating the need to stop and restart between layers, thus reducing total production time while maintaining high pressure resistance.
Solution Approach 2:
The pipe surface is preheated before reinforcing layer application, which prepares the surface in advance for immediate bonding. This eliminates the need for heating delays between layers, allowing continuous production and reducing overall manufacturing time while ensuring proper consolidation of each layer.
3Reliability
If reinforcing layers are fusion-bonded using infrared heating, then the structural integrity and reliability are improved, but the energy consumption increases
Solution Approach 1:
Infrared heating is used instead of conventional contact heating methods to consolidate the reinforcing layers. This non-contact heating method directly energizes the thermoplastic material, enabling rapid fusion bonding with high structural integrity while reducing energy consumption compared to traditional heating systems that lose heat to the surrounding environment.
Solution Approach 2:
The pipe and reinforcing layers are preheated before the final consolidation step. This preliminary heating reduces the temperature differential required during bonding, allowing the infrared heating system to achieve proper fusion with less energy input while ensuring reliable structural integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in a thermoplastic composite pipe that is both flexible and capable of withstanding high pressures, allowing for efficient transportation of media over long distances while maintaining robustness and durability.
Implementation Method 1
consolidating the at least one third layer of the reinforcement layer with at least one of the second layer of the reinforcement layer and the plastic pipe by means of a third heating device, in particular an infrared heating device
Implementation Method 2
At least one of the third layer of the reinforcement layer and the second layer of the reinforcement layer and the plastic pipe can be brought to a third temperature T3, in particular a temperature which leads to at least partial melting of at least one of the third layer of the reinforcement layer and the second layer of the reinforcement layer
Data Source
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AI summary
Method for producing a flexible, thermoplastic composite pipe (130), the method comprising the following steps: applying a first layer of a reinforcing layer to a plastic pipe (104); consolidating the first layer of the reinforcing layer with the plastic pipe (104), wherein at least the first layer of the reinforcing layer is brought to a first temperature (T1) which leads to at least partial melting of the first layer of the reinforcing layer, so that the first layer of the reinforcing layer and the plastic pipe (104) are firmly bonded together, in particular by fusion bonding; applying a second layer of the reinforcing layer to the first layer of the reinforcing layer;Consolidating the second layer of the reinforcing layer with at least the first layer of the reinforcing layer, wherein at least the second layer of the reinforcing layer is brought to a second temperature (T2) which leads to at least partial melting of the second layer of the reinforcing layer, so that the second layer of the reinforcing layer and the first layer of the reinforcing layer are firmly bonded together, in particular in a fusion-like manner; applying at least a third layer of the reinforcing layer to the second layer of the reinforcing layer;Consolidating at least one third layer of the reinforcing layer with at least the second layer of the reinforcing layer, wherein at least the third layer of the reinforcing layer is brought to a third temperature (T3) which leads to at least partial melting of the third layer of the reinforcing layer, so that the third layer of the reinforcing layer and the second layer of the reinforcing layer are firmly bonded together, in particular in a fusion-like manner, as well as thermoplastic composite pipe (130) and use of a thermoplastic composite pipe (130).